Chapter 4:

Machining Processes
for Various Shapes
Chapter Objectives
At the end of these chapter you will be able to
understand:
Introduction to milling machine classification,
principles and its operation
Planning and shaping machine and its principles
Broaching and slotting machine and its
principles
 Contents

•Milling
•Planning
•Shaping
•Broaching
•Slotting
 MILLING
Milling is a process of producing flat and complex
shapes with the use of multi-tooth cutting tool, which is
called a milling cutter and the cutting edges are called
teeth.
The axis of rotation of the cutting tool is perpendicular
to the direction of feed, either parallel or perpendicular
to the machined surface.

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The machine tool that traditionally
performs this operation is a milling
machine.
Milling is an interrupted cutting
operation: the teeth of the milling
cutter enter and exit the work during
each revolution.
 This interrupted cutting action
subjects the teeth to a cycle of impact
force and thermal shock on every
rotation.

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Rotating multiple-cutting-edge tool is moved across
work to cut a plane or straight surface
Two forms of milling: peripheral milling and face
milling

Fig.4.1 peripheral milling, and face milling.

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TYPES OF MILLING MACHINES

Milling machine rotates the cutter mounted on

the arbor of the machine and at the same time
automatically feed the work in the required
direction.
The milling machine may be classified in several
forms, but the choice of any particular machine is
determined primarily by the size of the workpiece
to be undertaken and operations to be performed.

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According to general design, the distinctive types of milling
machines are:

Column and knee type milling machines

a.Horizontal milling machine, Fig. 4(a)
b.Universal milling machine
c.Vertical milling machine Fig. 4(b)

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Fig.4.2 (a) knee and Column Horizontal milling Machine
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Fig.4.2 (b) knee and Column milling vertical Machine

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Planer milling machine

Fixed-bed type milling machine

(a) Simplex milling machine.
(b) Duplex milling machine.
(c) Triplex milling machine.
Machining center machines

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Fig.4.3 bed type simplex milling machine.
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Special types of milling machines

(a) Rotary table milling machine.

(b) Planetary milling machine.
(c) Profiling machine.
(d) Duplicating machine.
(e) Pantograph milling machine.
(f) Continuous milling machine.
(g) Drum milling machine
(h) Profiling and tracer controlled milling
machine 13
 Column and Knee Type Milling
Machine

Column and knee type milling machine

is the most commonly used milling
machine in general work shop .
In this type of milling machine the
table is mounted on the knee casting
which in turn is mounted on the vertical
slides of the main column.

14
The knee is vertically adjustable on the
column so that the table can be moved
up and down to accommodate work of
various heights.
 The column and knee type milling
machines are classified on the basis of
various methods of supplying power to
the table, different movements of the
table and different axis of rotation of
the main spindle.
Column and knee type milling machine
comprises of the following important
parts:-
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1.Base 9. Front brace
2.Column 10. Arbor support
3. Saddle 11. Arbor
4.Table 12.Overhanging arm
5. Elevating screw 13. Cutter
6. Knee 14. Cone pulley
7. Knee elevating 15. Telescopic feed
handle shaft.
8. Cross feed handle

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 SPINDLE

TRANSVERSELY TABLE
LONGITUDINALLY
COLUMN

KNEE

VERTICALLY
BASE

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Fig.4.4 Main machine elements of horizontal milling machine
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Planer Type Milling Machine

It is a heavy duty milling machine.

 It resembles a planer and like a
planning machine it has a cross rail
capable of being raised or lowered
carrying the cutters, their heads,
and the saddles, all supported by
rigid uprights.

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There may be a number of
independent spindles carrying cutters
on the rail at two heads on the
uprights.
The use of the machine is limited to
production work only and is considered
ultimate in metal re-moving capacity.

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Special Type Milling Machines

Milling machines of non-conventional

design have been developed to suit
special purposes.
The features that they have in
common are the spindle for rotating
the cutter and provision for moving
the tool or the work in different
directions.

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22
PRINCIPLE OF MILLING
In milling machine, the metal is cut
by means of a rotating cutter having
multiple cutting edges.
 For cutting operation, the work piece
is fed against the rotary cutter.
As the work piece moves against the
cutting edges of milling cutter, metal
is removed in form of chips.
Machined surface is formed in one or
more passes of the work.

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The work to be machined is held in
a vice, a rotary table, a three jaw
chuck, an index head, between
centers, in a special fixture or
bolted to machine table.
The rotary speed of the cutting
tool and the feed rate of the work
piece depend upon the type of
material being machined.

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Types of Milling methods

Peripheral milling
Peripheral milling is a milling method
which functions with horizontal tool
axis.
The cutting edges of the plain
milling cutter are located at the
tool’s periphery.
Peripheral milling is subdivided into
up- and down milling.
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UP-Milling or Conventional Milling

In the up-milling or conventional

milling, as shown in Fig. below, the
metal is removed in form of small
chips by a cutter rotating against
the direction of travel of the work
piece.
In this type of milling, the chip
thickness is minimum at the start
of the cut and maximum at the end
of cut.

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As a result the cutting force also
varies from zero to the maximum
value per tooth movement of the
milling cutter.
 The major disadvantages of up-
milling process are the tendency of
cutting force to lift the work from
the fixtures and poor surface
finish obtained.
 But being a safer process, it is
commonly used method of milling.

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Fig.4.6 Principal of up-milling

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 Down-Milling or Climb Milling
Down milling is shown in Fig. below It
is also known as climb milling.
In this method, the metal is removed
by a cutter rotating in the same
direction of feed of the workpiece.
The effect of this is that the teeth
cut downward instead of upwards.
 Chip thickness is maximum at the
start of the cut and minimum in the
end.

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In this method, it is claimed that
there is less friction involved and
consequently less heat is generated
on the contact surface of the
cutter and workpiece.
Climb milling can be used
advantageously on many kinds of
work to increase the number of
pieces per sharpening and to
produce a better finish.

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With climb milling, saws cut long
thin slots more satisfactorily than
with standard milling.
 Another advantage is that slightly
lower power consumption is obtainable
by climb milling, since there is no
need to drive the table against the
cutter

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Fig.4.7 Principal of down-milling

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Milling Operations
Plain milling or slab
milling
It is a method of
producing a plain,
flat, horizontal
surface parallel to
the axis of rotation
of the cutter.

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Face milling
It is a method of
producing a flat surface
at right angles to the
axis of the cutter.
Side milling
It is the operation of
production of a flat
vertical surface on the
side of a work-piece by
using a side milling
cutter.
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Angular milling
It is a method of
producing a flat surface
making an angle to the
axis of the cutter.

12/03/23 35
Form milling
It is, a method of producing a
surface having an irregular outline.
End milling
It is a method of milling slots, flat
surfaces, and profiles by end mills.

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Profile milling
It is the operation of reproduction of an
outline of a template or complex shape of a
master die on a workpiece.
Saw milling
It is a method of producing deep slots and
cutting materials into the required length by
slitting saws.

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T-slot milling
It is a process of milling T-slot
in to tables, and beds of
machine tools for fixing bolt
heads through.
Keyway milling
This is the processes of milling slots for
the seat of keys to prevent relative
motions between machine members

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Gear cutting milling
Is a process of producing
gears on milling machine.
There are variety of method
For gear production
Helical milling

Is the process in which the

machine table is rotated through a
helix angle.
 The machine lead screw drives
the dividing head.
Work is rotated while the machine
table feeds. 39
Straddle milling
When two or more parallel vertical
surfaces are machined at a single cut, the
operation is called straddle milling.
Straddle milling is accomplished by
mounting two side milling cutters on the
same arbor, fig 4.9, set apart at an exact
spacing.

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Two sides of the workpiece are machined
simultaneously and final width dimensions are
exactly controlled.

Fig.4.9straddle milling.
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Gang milling

Gang milling is the term applied to an

operation in which two or more milling cutters
are mounted on the same arbor and used when
cutting horizontal surfaces.
All cutters may perform the same type of
operation or each cutter may perform a
different type of operation.

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For example, several workplaces need a slot,
a flat surface, and an angular groove.
The best method to cut these would be gang
milling as shown in Figure shown below
 All the completed workplaces would be the
same.

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12/03/23
Fig.4.10 Gang milling
Department of Production Engineering 44
 Indexing
• Indexing is the operation of dividing the periphery
of a piece of work into any number of equal parts.
• In cutting spur gear, equal spacing of teeth on the
gear blank is performed by indexing.
• The indexing operation can be also adapted for
producing hexagonal and square headed bolts,
cutting splines on shafts, fluting drills, tap and
reamers and many other jobs, all requiring the
periphery of the workpiece to be divided equally
and accurately.

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• Indexing is accomplished by using a special
attachment known as dividing head or index
head.
• The dividing heads are of three types:
1.Plain or simple dividing head
2.Universal dividing head and
3.Optical dividing head

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 Plain or Simple Dividing Head
• The plain dividing head comprises a cylindrical
spindle housed in a frame and a base bolted to
the machine table.
• The index crank is connected to the tail-end of
the spindle directly, and the crank and the spindle
rotate as one unit.
• The indexing plate is mounted on the spindle and
rotates with it.
• The spindle may be rotated through the desired
angle and then clamped by inserting the clamping
lever pin into any one of equally spaced holes or
slots cut.
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• The work is mounted at the nose end of the spindle by
chuck or may be supported between centers.
• The live center is fitted at the nose of the spindle and
dead center is held by tailstock.

Fig 5.10 the index head and foot stock

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Fig 5.11 Simple Indexing Head
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 Universal Dividing Head
• The universal dividing head shown in Fig 5.12. is
the most common type of indexing arrangements
used in workshop.

• As the name implies this type of index head can

be used to execute all forms of indexing.

• A universal indexing head is used for the

following purposes:

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1. For setting the work in vertical, horizontal or in
inclined positions, relative to the table surface.

2. For turning the workpiece periodically through a

given angle to impart indexing movement.

3. For imparting a continuous rotary motion to the

workpiece for milling helical grooves.

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Fig 5.12 Universal Dividing Head
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 Optical Dividing Head

• The optical dividing heads (Fig 5.13) are used for

precise angular indexing during machining, and for
checking the accuracy of various angular surfaces.

• The mechanism comprises a worm gear which is keyed

to the spindle and may be rotated by worm.

• A circular glass scale graduated in 1 degree division is

rigidly mounted on the worm wheel.

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• Any movement of the spindle affected by
rotating the worm is read off by means of a
microscope fitted on the dividing head body.
• The reading on the circular glass scale is
projected through prisms on the screen of the
microscopic eye piece.
• The eye piece has a scale having 60 divisions and
each division is equivalent to 1 minutes movement
of the circular scale.
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Fig 5.13 Optical Dividing Head
[email protected]
 Indexing Methods
• There are several different methods of indexing.
The choice of any one method depends upon the
number of divisions required and the type of
dividing head used.
• The following are the different methods of
indexing:
1. Direct or rapid indexing
2. Plain or simple indexing
3. Compound indexing
4.Differential indexing
5. Angular indexing
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 Direct Indexing
• Direct indexing, often called rapid indexing, is used when
a large number of identical pieces are indexed by very
small divisions.
• The operation may be performed in both plain and
universal dividing head.
• With a rapid index plate having 24 holes it is possible to
divide the work into equal divisions of 2,3,4,6,8,12, and 24
parts which are all factors of 24.
• Rules for direct indexing:
No. of holes to be moved = 24/N
Where, N = Number of divisions required

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Example:

Find out the index movements required to mill

a hexagonal bolt by direct indexing. The rapid
index plate has 24 holes.

No. of holes to be moved = 24/6 = 4

• After machining one side of the bolt the index

plate will have to be moved by 4 holes for 5
number of times to machine the remaining face of
the bolt.
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 Simple Indexing

• The simple indexing, sometimes called plain

indexing is more accurate and suitable for
numbers beyond the range of rapid indexing.
• Index plates with circles of holes patented by
the Brown and Sharpe manufacturing company
are as follows:
Plate No. 1 :- 15, 16, 17, 18, 19, 20
Plate No. 2 :-21, 23, 27, 29, 31, 33
Plate No. 3 :- 37, 39, 41, 43, 47, 49

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• The index plate used on Cincinnati and Parkinson
dividing heads is of larger diameter than the Brown
and Sharpe index plates.
• The number of holes in each side patented by the
Cincinnati and Parkinson manufacturing company are as
follows:
First side – 24, 25, 28, 30, 34, 37, 38, 39, 41, 42, 43
Second side – 46, 47, 49, 51, 53, 54, 57, 58, 59, 62, 66

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 Rules for Simple Indexing

• To find the index crank movement, divided 40 by the

number of divisions required on the work.

• The formula for index crank movement is given

below:

Index crank movement = 40/N

Where N = Number of division required

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Example

Set the dividing head to mill 30 teeth on a spur

wheel blank.

Thus for indexing, one complete turn and 7

holes in 21 hole circle of the index plate will
have to be moved by the index crank.

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Tool holding Devices

plain milling cutters

• The task of the tool holders is to tightly and
reliably fix the milling cutters to the milling
spindle of the machine.
• The fastening element for the milling cutters is
adopted in the inner taper of the milling spindle
and centered.
• Torque occurring during milling is transmitted
through frictional resistance in the taper.
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Alignment of the milling-cutter
arbour, supported in the steady
rest of the milling machine 64
 Shell end mill arbors
• Shell end mill arbors are limited according to
length and work without any support by an
additional bearing.

Shell end mill arbor

with keyway

Shell end mill arbor

with cross-slot

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Milling adaptors
• Milling adaptors are used to mount end mill
cutters with Morse taper and tapped shank
• For this reason, a hexagon socket screw is
inside the milling collet, and the milling cutter
shank is pulled with this screw into the Morse
taper.

Milling adaptor for tools with

Morse taper and tapped shank

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 Milling collet

Milling collet for milling cutters

with cylindrical shank
• The milling collet is used to a) for milling cutters with
clamp milling cutters with lateral lock-in area
cylinder shank. b) clamping chuck with collet
• The collet with clamping b1 standard collet
screws is used for milling b2 collet for milling cutters
cutters with lateral lock-in with external thread
area. b3 short collet able to chuck
also twist drills on the margin.
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Work Holding Devices

• It is necessary that the work should be

properly and securely held on the milling
machine table for effective machining
operations.

• The following are the usual method of

holding work on the table.

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T- slot and Clamp
• Bulky workpieces of irregular shapes are clamped directly
on the milling machine table by using T-bolts and clamps.
Different design of clamps are used for different
patterns of work.
Angle plates
• When work surfaces are to be milled at right angles to
another face, angle plates are used for supporting the
work.
• The angle plate is bolted on the table and the workpiece is
supported on its face by bolts and clamps
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V- blocks
• The V-blocks are used for holding shafts on milling machine
table in which keyways, slots and flats to be milled.
• The blocks are clamped on the machine table by the straps and
bolts.

Vises
• Vises are the most common appliances for holding work on
milling machine table due to its quick loading and unloading
arrangement.
• There are mainly three types of vises commonly used in milling
machines. They are plain vise, swivel vise and tool makers
universal vise.
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Plain vise

• The plain vise bolted directly on the milling

machine table is the most common type of
machine vise used for plain milling operations.

• Work is clamped between the fixed and

movable jaw.

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Swivel vise

• The swivel vise is used to mill an angular surface

in relation to a straight surface without removing
the work from the vise.

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Tool maker universal vise

• The universal vise can be swiveled in a horizontal

plane similar to a swivel vise and can also be tilted
in any vertical position for angular cut.

73
Special Jigs & Fixtures
• The fixtures & jigs are special devices
designed to hold work for specific operations
more efficiently than standard work holding
devices.
• Fixtures & jigs are specially useful when large
numbers of identical parts are being produced.
By using fixtures & jigs loading, locating,
clamping, and unloading time is greatly
minimized.
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Special Jig & Fixture 75
 SHAPER MACHINE
Introduction
A shaper is a machine with a
reciprocating tool.
Uses lathe type tool to cuts work in the
straight line.
By successive movement of tool, flat
surface is generated.
The flat surface may be horizontal,
vertical or inclined.

76
With special tools and attachments,
external and internal key ways, spiral,
grooves, dovetails and T-slots can be
obtained.

77
 Cont.
It is a relatively slow machine in relation
to the rate of metal removal, since the
shaper cuts only on the forward stroke.
Shapers use reciprocating motion with:
 For ward stroke (cutting motion)
 Backward stroke (non cutting stroke)

78
Types of shapers
 Shapers are classified under the following
headings:
1. According to the type of mechanism
a. Crank type
b. Geared type
c. Hydraulic type
2. According to the design of table
a) Standard shaper
b) Universal shaper
3. According to the position and travel of ram
a. Horizontal type
b. Vertical type
4. According to the type of cutting stroke
a. Push type
b. Draw type

79
The most common type of shaper is horizontal
shaper they can be:
 Mechanically driven crank and rocker)
 Hydraulicacaly driving (cylinder and piston)

80
Shaper Parts:

81
Shaper specification
Define by maximum stroke length usually ranges from
175 to 900mm.
Other are type of drive (belt or individual motor drive),
floor space required ,
weight of the machine ,
cutting to return ratio,
power input etc.

82
 Principle of Working
The central large bull gear receives its rotation from
the motor through the belt-pulley, clutch, speed gear
box and then the pinion.
The rotation of the crank causes oscillation of the
link and thereby reciprocation of the ram and hence
the tool in straight path

Cutting velocity which needs to

be varied depending upon the
tool-work materials, depends upon
The stroke length, S mm
Number of strokes per min.,
Ns and
The Quick return ratio, QRR
(ratio of the durations of the
forward stroke and the return 83
Clearly the time taken to complete forward stroke is
proportional to angle α (refer to Fig. (b)) and the return
stroke is completed in less time which is proportional to
angle β.

84
Mechanism of a Hydraulic Shaper
A hydraulic shaper has the same major parts as the
mechanical one.
 However, the ram is driven by a hydraulic cylinder.
The speeds of the shaper ram and the feeds of the work
table are controlled by hydraulic mechanism.
 A lever operates a valve that varies the quantity of oil
delivered to the rain cylinder and thereby governs the ram
speed.

A - Return stroke B - Shaper ram

C - Cutting Stroke D - Base
F - Pump
E - 4- Way value
G - Motor

85
The amount of cross or vertical feed of the table is
regulated by a hand wheel which affects the table feed
cylinder.
The return or idle stroke is
faster than the cutting stroke
because of the smaller area in
the return side of the cylinder
(due to the presence of piston
rod) if a constant volume pump is
used.

86
The advantages of hydraulic shaper
The cutting and the return stroke speeds are
practically constant through out the stroke
The reversal of the ram is obtained quickly with out
any shock as the oil on the other end of the cylinder
provides cushioning effect
Infinite number of cutting speeds & feeds may be
obtained from zero to the maximum value
It can easily be controlled
The relief valve ensures safety to the tool when the
machine is overloaded

87
Shaper cutting tools
Shaper operations vary from producing a flat surface
to producing contours, grooves, and various intricate
shapes.
To produce these surfaces, a wide variety of cutting
tools ground at different shapes and angles is
required.
Shaper tool bit angles

Type of angle Amount of angle

Clearance angle (side) 20 - 40
Front clearance angle 40
Side rake angle 100 - 200

88
 Setting shaper stroke
It is good practice not to have the shaper stroke
any longer than necessary.
A stroke, which longer would only waste time and
take longer machining time.
 The length of the stroke should be about 25.4 mm
longer than the work surface to be cut. This allows
the cutting tool to clear each end of the work by
12.7 mm.

89
 Cont.

To set the shaper stroke length

Measure the length of the work piece
and add 25 mm to the length
Start the shaper and stop it when the
ram is at the back of the stroke
Loosen the stroke regulator lock nut
Adjust to the length required by
turning the stroke regulator screw
Tighten the stroke regulator lock cut

90
  Feed mechanisms
The fed can be given by hand or automatically
Feed mechanism is given only at the end of the return
stroke
Cross feed movement is given to the table for
machining flat horizontal surfaces
Vertical and inclined surfaces are machined by feeding
the tool head by hand
Hand feed
 The table is moved horizontally in a direction
perpendicular to the ram movement and this is called
cross feed
 Cross feed is given by rotating the cross feed screw
and this passes through a nut attached to the table

91
The vertical adjustment of the
table is necessary to hold work
piece of various heights
• This is done by rotating the
elevating screw through the
horizontal rod
Vertical feed or down feed is
given by the tool head
• The tool slide of the tool head is
moved towards by rotating the
down feed screw
Angular feed is given through the
tool head after setting it to the
required angle
92
Automatic table feed
Setting table feed
When machining horizontal surface, the table
automatically feed the work piece secured to it toward
the cutting tool on the return stroke of the ram. If the
table feed were to operate on the cutting or forward
stroke, the cutting tool would be damaged and the work
surface would be made rough and irregular.

93
 Shaping operations
Machining:-

Horizontal surfaces
vertical surfaces
angular surfaces
Slots, grooves, key ways
Irregular surfaces
Spines or cutting gears

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95
96
97
 CUTTING TOOLS USED IN SHAPING
 The cutting tools for shapers are generally made of
H.S.S., either solid or with brazed tips.
 Due to interrupted cuts, tungsten carbide tools are not
preferred for shaping work. These tools are made sturdy
with fairly generous size for shank and tip.

98
Fig. Cutting tools used in shaping work
Work Holding devices

99
 Shaper cutting parameters

Cutting speed
It is the rate at which the metal is removed by the
cutting tool and expressed in meters per minutes
It depends up on three factors;
Work material being cut
Its length and
The type of cutting tool used

100
 Cont.
The cutting speed (V) is considered only during the forward
stroke
V = length of cutting stroke / time required by the cutting stroke
Time taken by the cutting stroke
= length of the cutting stroke in mm / cutting speed in meter per min.
= L / 1000V
And m = return stroke time / cutting stroke time
Therefore Return stroke time = m x cutting stroke time
= m x (L /1000V) = m L / 1000V
Time taken for one double stroke = (L /1000V) + (m L / 1000V)

T = (L /1000V) (1+m) ………………………(1)

101
 Cont.

Number of double strokes / minutes.= 1 / [(L /1000V)

(1+m)] = n
Or (Rpm of the bull gear)

n = 1000V / L (1+m) =>

V =n [L (1+m)] /1000……………………………(2)
L= cutting stroke in mm
m= the ratio between return time to cutting time
n= the no of double strokes of the ram per minutes or
Rpm of bull gear
102
Feed
 Is defined as the distance the work is moved side ways to
work the cutting tool for each forward, stroke of the ram.
It is the relative movement of the tool or work in a direction
perpendicular to the movement of the ram and expressed in
mm. per strokes
The feed is always given at the end of the return stroke
factors must be considered.
 The type of material being cut
 The type of cut (roughing or finishing)
 The type of cutting tool used
 “ surface finish required

103
Depth of cut
The thickness of the metal removed in one cut
Machining time
Time taken to complete one double stroke= L(1+m) / 1000V
Total no of double strokes required to complete the job = B / S
where ;

Total time taken to complete the job = LB(1+m)/ 1000VS

B = the width of the work in mm

S = the feed expressed in mm / double stroke

104
Example :
A cast iron plate measuring 300mmx100mmx40mm is to be rough shaped
along its wider face . Calculate the machining time.
Approach length = Over travel length= 25 mm
Cutting speed = 12 m/ min ,Return speed =20 m/ min , ; Feed per cycle = 1
mm
Allowance on either side of the plate width= 5 mm.
Solution
Length of stroke (L) = 300 +25+25 = 350mm
Cutting stroke time =L/ V1 = 350 / (1000x12) = 0.029 minutes
Return stroke time = L/ V2 = 350 / (1000x20) = 0.0175 minutes
m= [ L/ V2 ] / [ L/ V1 ] = 0.0175 / 0.029 = 0.6
B (shaping width) = 100+5+5 =110 mm
Machining time=LB(1+m)/ 1000VS= [ 350 x110(1+0.6)]/ [1000x12x1]
= 5.13 minutes
105
Example.
Calculate the machining time required for taking a complete cut along the
length by two rough cuts and one finish cut on a gray cast iron plate of length
800mm by 600 mm width.

Cutting speed = 12 m/ min

Return time to cutting time ratio is 3:2
Feed =1.5 mm / cycle
Allowance length wise = 20 mm
Allowance width wise = 5 mm

106
Solution
No of passes = 3; Length of stroke (L)= 20 +800 + 20= 840mm
Time for cutting stroke (tc) = L/ Vc = 0.84/12 = 0.07 min
Time for return stroke (tr) = L/ Vr = 0.84/18 = 0.0466 min
tm =Time for cutting stroke (tc) + Time for return stroke (tr)
= 0.07 + 0.0466 =0.1166 min
Shaping width (B) = 5+600+5= 610 mm.

No of cycles required per cut (n)= B / S = 610 mm / 1.5 mm per cycle=406 cycles

Time required per cut = n x tm = 406 x 0.1166 =47.3 min

Total machining time required for taking a complete cut = n x t m x no of passes
=406 x 0.1166 x3 min =140 min= 2 hrs.20 min.

107
Problems
1. Determine the machining time for machining a M.S plate of 400mmx
300mm by one rough cut and one finish cut with the following data:
Cutting speed = 15 m/ min
Return speed =25 m/ min
Feed = 1.2 mm / cycle
Length wise approach and over run are 30 &20 mm respectively
Assume if any data is missing

108
2. Determine the machining time of a square plate 500 mm2 made of
brass for three passes.

Cutting speed = 25 m/ min

Return / cutting ratio is 2:1
Feed = 0.8 mm / cycle
Length wise approach and over run are 30 &10 mm respectively
Allowance on either side of the plate width= 5 mm

109
 PLANNER MACHINE
Definition
• The planner is a machine tool used to machine flat or
plane surfaces on work that is fastened to a
reciprocating table

• The surface can be horizontal, vertical or angular

• The planner can also be used in-order to form

irregular and curved surfaces
• The planner differs from the shaper in the worktable moves
back and forth with a reciprocating motion while the cutting
tool held stationery, except for traverse movement.
• The planner can be used for the same purpose as shaper, but
it can handle much larger work, and heavier cuts can be
taken.
• And the feed is supplied by the lateral movement of the tool,
where as in a shaper the tool which is mounted up on the ram
reciprocates & the feed is given by the crosswise movement
of the table
• Planner is very large and massive compared to a shaper and
capable of machining heavy workpieces which can not be
accommodate on a shaper table
Comparison of a planner and shaper
 Principle of operation
• In a planer work is held on the table
• The work reciprocates over the table
• There is one or two vertical columns and are
connected at the top by the over arm
• The columns have vertical guide ways and the
cross rail slides vertically along these guide
ways
• The cross rail has horizontal guide ways and
one or more number of tool heads slide along
these guide ways
• These tool heads are called vertical tool
heads
 Types of Planners
• One of the more common types of planner is the double
column planner.
• Two columns support the cross rail and house the elevating
screws and controls for the machine.
• The open side planner has the only one column or housing to
support the cross rail and tool heads.
–One advantage of this type of planner is that workpiece of
irregular shape can be handled with the workpiece
extending outward over the side of the table
• The rated size or capacity of a planner as given by the
manufacturer refers to the width, height and length of the
largest workpiece that can be machined.
Planner Tools
 Planning Operations.
• Planning horizontal surface
• A typical example of a work that can be machined
horizontally is the flanged cast iron cover.
• Planning at an angle
• Planning must be performed at a given angle for dovetails,
V-shaped grooves and so on. The tool-head assembly must
be pivoted with respect to the saddle so that it can swing
around the center axis.
• Planning curved surfaces
• A fixture consisting of a radius arm pivoted on a
bracket can be used to plane a concave surface.
• The feed screw of the slide is removed, and the
slide is fastened to the radius arm.
 BROACHING
• The broaching process may be applied in machining holes or other
internal surfaces and also to many flat or other external surfaces.

• Broaching is a machining operation that involves the use of a

multiple-tooth cutting tool moved linearly relative to the workpiece
in the direction of the tool axis:

• The cutting tool is called a broach, and the machine tool is called a
broaching machine.
• The shape of the machined surface is determined by the contour
of the cutting edges on the broach, particularly the shape of final
cutting teeth.
Various shapes produced by internal
broaching operation
• The broaching process is very rapid, accurate, and it leaves
a finish of good quality.

• It is employed extensively in automotive and other plants

where duplicate parts must be produced in large quantities
and frequently to given dimensions within small tolerances.
 Types of Broaches
• A number of typical broaches and the operations for
which they are intended
Broaching tools
The terminology of the broach is shown in the figure:

Most broaches are made of high-speed steel, although

broaches with carbide inserts either brazed or mechanically
attached are also available.
 Broaching - Advantages
Production rates are high
Rough to finish in one pass
Cutting time is quick
Rapid load and unload of parts
 External and internal features
 Any form that can be produced on a broaching tool
can be produced
 Production tolerances are excellent
Surface finishes are equal to milling
 Operator skill is low
 Broaching -Disadvantages
Tooling cost can be high
In some cases--not suited for low
production rates
Parts to be broached must be strong
enough to withstand the forces of the
process
Surface to be broached must be
accessible
Methods of operation

Pull broaching - broach is pulled through or

across stationary work
Push broaching - broach is pushed through
or across work
Surface broaching - either the work or the
broach moves across the other
 Broaching machines
• There is no relative feed motion that is carried out by either the tool
or the work. It makes the kinematics of the broaching machine quite
simple.
 2.11 Introduction to Slotter
• The slotter or slotting machine is also a
reciprocating type of machine tool similar to a
shaper or a planer. It may be considered as a
vertical shaper.
• The chief difference between a shaper and a
slotter is the direction of the cutting action.
• The machine operates in a manner similar to the
shaper, however, the tool moves vertically rather
than in a horizontal direction.
• The job is held stationary. The slotter has a
vertical ram and a hand or power operated rotary
table.
132
 2.12Types of Slotting Machine
Puncher Slotter
• The puncher slotter is a heavy, rigid machine
designed for removal of large amount of metal
from large forgings or castings
• The length of stroke of a puncher slotter is
sufficiently large. It may be as long as 1800 to
2000 mm.
• The puncher slotter ram is usually driven by a
spiral pinion meshing with the rack teeth cut
on the under side of the ram
• The pinion is driven a variable speed
reversible electric motor similar to that of a
planer. The feed is also controlled by
electrical gears. 133
Precision Slotter
• The precision slotter is a lighter machine and is operated at high speeds.
• The machine is designed to take light cuts giving accurate finish. Using
special jigs, the machine can handle a number of identical works on a
production basis.
• The precision machines are also used for general purpose work and are
usually fitted with whitworth quick return mechanism.

134
2.13 Principal Parts of Slotter

135
Bed or Base
• It is made up of cast iron. It supports column,
tables, ram, driving mechanism etc. The top of
the bed carries horizontal ways along which the
worktable can traverse.
Table
• It holds the work piece and is adjustable in
longitudinal and cross-wise directions. The table
can be rotated about its centre.
Hand wheels
• They are provided for rotating the table and for
longitudinal and cross traverse.

136
Column is the vertical member
• They are made up of cast iron and it houses the
driving mechanism. The vertical front face of the
column is accurately finished for providing ways
along which the ram moves up and down.
Ram
• It is provided to reciprocate vertically up and
down. At its bottom, it carries the cutting tool. It
is similar to the ram of a shaper; but it is more
massive and moves vertically, at right angle to the
worktable, instead of having the horizontal motion
of a shaper:
Cross-slide
• It can be moved parallel to the face of the
column. The circular work-table is mounted on the
top of the cross-slide.

137
 2.14 Ram Drive Mechanism
• A slotter removes metal during downward cutting
stroke only whereas during return upward return
stroke no metal is removed
• To reduce the idle time quick return mechanism
is incorporated in the machine. The usual types of
ram drive mechanisms are:
1. Whitworth quick return mechanism
2. Variable speed reversible motor drive
mechanism
3. Hydraulic drive mechanism

138
 2.15 Operations Performed on
Slotting Machine
• A slotter is a very economical machine tool when
used for certain classes of work given as under:
1. It is used for machining vertical surfaces
2. It is used angular or inclined surfaces
3.It is used to cut slots, splines keyways for both
internal and external jobs such as machining
internal and external gears,
4.It is used for works as machining concave,
circular, semi-circular and convex surfaces

139
5. It is used for shaping internal and external
forms or profiles
6. It is used for machining of shapes which are
difficult to produce on shaper
7. It is used for internal machining of blind holes
8. It is used for machining dies and punches
• Since a slotter works slowly. It has less use in
mass production work. It can be substituted
by the broaching machine.

140
The End of
Chapter-
4